Delivering Innovation: Zeton Designs and Builds Modular Demonstration Plant for Travertine Technologies

November 10, 2025

Zeton recently completed the design and fabrication of a modular demonstration plant for Travertine Technologies, a U.S.-based company developing a novel electrochemical process for carbon-negative critical chemical and mineral production. The plant, now installed in Rochester, NY, is a key step in scaling Travertine’s process. This plant uses Travertine’s core process to upcycle waste gypsum and carbon dioxide from the air into sulfuric acid used in mineral extraction and fertilizer production and calcium carbonate which can be blended into cement.

Travertine’s process posed unique engineering challenges, requiring a custom modular solution capable of integrating electrochemical reactors, gas handling systems, and solid-liquid separation—all within a compact footprint suitable for rapid deployment and scale-up. Zeton’s team worked closely with Travertine to translate data from their continuous lab-scale pilot into a fully functional demonstration unit.

One of the most intricate aspects of the project was managing the piping layout and drainage design around the electrolyzer system. The relatively small plant footprint introduced routing constraints that required creative solutions to maintain accessibility and ensure mechanical integrity. Achieving reliable free-draining from the electrolyzer to the recirculation tanks was particularly complex, requiring close coordination between equipment design and layout to ensure proper elevation, slope, and support. These challenges were met through thoughtful planning and collaboration, resulting in a robust and efficient configuration.

The completed plant enables Travertine to validate its technology under real-world conditions, and gain critical data for their first commercial plant. Zeton’s modular approach provided the flexibility and speed needed to meet aggressive timelines and accommodate future process iterations.

“Zeton is the expert in pilot and demo plant design and construction. Having all disciplines and trades housed under one roof and a single project manager from design through construction is rare and critical for success in first-of-a-kind projects like ours.” Owen Cadwalader, COO.